Fabric for clothing, and production method of fabric for clothing

Abstract

To provide a fabric for clothing having both of thinness and strength, and a production method of a fabric for clothing.SOLUTION: A fabric S for clothing has a multilayer structure including a first layer L1 having air permeability and a second layer L2 composed of fibrillated fibers mixed with a treatment agent.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a clothing fabric and a method for manufacturing the clothing fabric. [Background technology]

[0002] Nonwoven fabrics have been known in the past. For example, Patent Document 1 discloses a mask made of a nonwoven fabric. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2022-157261 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, the nonwoven fabric described in Patent Document 1 has a problem in that it is difficult to achieve both thinness and strength when used for clothing. In particular, when processed into clothing and worn, there is a possibility that the fabric may tear due to insufficient strength. In addition, when the fabric is made thicker to improve strength, the flexibility of the fabric may decrease, and the feel and texture may be impaired. In other words, there has been a demand for a nonwoven fabric for clothing that is both thin and strong. [Means for solving the problem]

[0005] The clothing fabric has a multi-layer structure including a first layer having breathability and a second layer formed by mixing defibrated fibers with a treatment agent.

[0006] The method for manufacturing fabrics for clothing includes a defibrating process in which fabric is dry-defibrated to produce fibers, a mixing process in which a treatment agent is mixed with the fibers to produce a mixture, a depositing process in which the mixture is deposited in the air on a breathable fabric that constitutes a first layer to produce a web that constitutes a second layer, and a shaping process in which the fabric and the web are pressurized and heated to form the web. [Brief description of the drawings]

[0007] [Figure 1] FIG. 2 is a schematic cross-sectional view showing the configuration of the clothing fabric according to the embodiment. [Diagram 2] 1 is a flow diagram showing a method for manufacturing a fabric for clothing. [Diagram 3] FIG. 1 is a schematic diagram showing the configuration of a fabric manufacturing device used to manufacture clothing fabric. [Figure 4] 1 is a table showing the manufacturing conditions and evaluation results of clothing fabrics according to examples and comparative examples. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] In the following embodiments, a clothing fabric manufactured by a dry process and a manufacturing method thereof will be exemplified and described with reference to the drawings. In this specification, the term "dry process" refers to a process carried out in air such as atmosphere, rather than in a liquid such as water. Note that the clothing fabric of the present invention is not limited to being manufactured by a dry process.

[0009] In the following figures, XYZ axes are added as mutually orthogonal coordinate axes as necessary, the direction of each arrow is the + direction, and the direction opposite to the + direction is the - direction. The Z axis is a virtual axis along the vertical direction, with the +Z direction being the upward direction and the -Z direction being the downward direction.

[0010] In the fabric manufacturing apparatus 1, the direction ahead in the transport direction of the raw materials, webs, and clothing fabrics is sometimes referred to as the downstream side, and the direction going upstream in the transport direction is sometimes referred to as the upstream side. For convenience of illustration, the sizes of the various members are different from the actual sizes.

[0011] 1. Fabric for clothing As shown in Fig. 1, the clothing fabric S according to this embodiment has a multi-layer structure including a first layer L1 and a second layer L2. The first layer L1 includes a base layer L1b and an adhesive layer L1a. The clothing fabric S is formed by laminating the base layer L1b of the first layer L1, the adhesive layer L1a of the first layer L1, and the second layer L2 in this order from bottom to top. When the clothing fabric S is processed into clothing, either the first layer L1 or the second layer L2 may be used on the front side of the clothing.

[0012] The thickness of the clothing fabric S is appropriately set according to the use and form of the clothing to which it is applied. The thickness of the clothing fabric S is not particularly limited, but is set to, for example, 0.30 mm or more and 1.50 mm or less. This allows the flexibility and strength of the clothing fabric S to be improved.

[0013] The first layer L1 is breathable. If the second layer L2 is also breathable, the first layer L1 does not prevent ventilation, and breathability is imparted to the clothing fabric S. This prevents the clothing fabric S from becoming stuffy when worn as clothing.

[0014] In addition, in the production of the clothing fabric S, the breathability of the first layer L1 can be used to promote the formation of fibers, etc., which will become the second layer L2, on the first layer L1. Specifically, the formation of a web containing fibers is promoted by sucking air in which fibers, etc. are dispersed, through the first layer L1. The production method and production process of the clothing fabric S will be described later in the section on the clothing fabric production method.

[0015] In this specification, air permeability is defined as the amount of air passing through a test piece according to the JIS air permeability test (L1096 2010 8.26.1 A method). In this specification, air permeability means that the amount of air measured by the above test method is 10 cm 3 / cm 2 This means that the time is longer than 1 second.

[0016] The thickness of the first layer L1 is not particularly limited, but is preferably set to, for example, 0.01 mm or more and 0.20 mm or less, which can improve the flexibility and strength of the clothing fabric S.

[0017] The base material layer L1b has breathability. The base material layer L1b forms one surface of the clothing fabric S. Incidentally, the second layer L2 forms the other surface of the clothing fabric S.

[0018] The base material layer L1b is a sheet of polyester-containing woven fabric, knitted fabric, nonwoven fabric, etc. Since polyester has relatively excellent strength, the thinness and strength of the clothing fabric S can be further improved.

[0019] The base layer L1b is not limited to being made of polyester, and may be a sheet containing polyester and other resin, or may be a sheet made of a resin other than polyester.

[0020] The adhesive layer L1a is interposed between the base layer L1b and the second layer L2. The adhesive layer L1a bonds the first layer L1 and the second layer L2 relatively strongly, and therefore the peel strength between the first layer L1 and the second layer L2 can be improved.

[0021] Materials for the adhesive layer L1a include known adhesives such as polyester resin, acrylic resin, silicone resin, and urethane resin, and known adhesives such as epoxy, acrylic, cyanoacrylate, urethane, and vinyl acetate. When an adhesive is used as the adhesive layer L1a, the adhesive layer L1a may be cured by heat applied in a molding step in the manufacturing process of the clothing fabric S.

[0022] The adhesive layer L1a also has air permeability. Specifically, the adhesive layer L1a is formed so as not to inhibit the air permeability of the first layer L1. Examples of the form of such an adhesive layer L1a include one in which the above-mentioned adhesive or adhesive is applied in a planar mesh pattern, one having a plurality of holes penetrating in the direction along the Z axis, and the like.

[0023] The adhesive layer L1a is not an essential component, and the first layer L1 may be composed of only the base layer L1b. In this case, the first layer L1 and the second layer L2 are bonded together by applying pressure and heat in the molding process in the manufacturing process of the clothing fabric S.

[0024] The first layer L1 may be colored. When the base layer L1b and the adhesive layer L1a are made of the above-mentioned materials, they generally have a white color. Therefore, if the second layer L2 is colored, the color of the first layer L1 and the second layer L2 will be relatively significantly different. When the clothing fabric S is processed into clothing, the difference in color between the first layer L1 and the second layer L2 is easily noticeable. In contrast, when the first layer L1 is colored in a color close to that of the second layer L2, the difference in color can be made less noticeable when processed into clothing. In addition, when the first layer L1 is used to be the surface side of the clothing, coloring it in various colors improves the design.

[0025] The coloring of the first layer L1 may be performed on one of the surfaces of the clothing fabric S. The coloring of the first layer L1 is not particularly limited, and a known method such as digital printing or analog printing, such as an inkjet method, can be applied. The coloring of the first layer L1 may be performed at the manufacturing stage of the first layer L1, or may be performed during the manufacturing process of the clothing fabric S.

[0026] The second layer L2 is a nonwoven fabric formed by mixing defibrated fibers with a treatment agent such as a binder. In the following description, the defibrated fibers may be simply referred to as fibers.

[0027] The basis weight of the second layer L2 is 100 g / m 2 More than 180g / m 2 It is preferable that the basis weight is equal to or less than 100 g / m2. The basis weight is the number of grams per square meter of the surface area along the XY plane of one piece of clothing fabric S. By setting the basis weight of the second layer L2 within the above range, it is possible to ensure a balance between thinness and strength in the second layer L2. Therefore, the thinness and strength of the clothing fabric S can be further improved.

[0028] The basis weight of the second layer L2 is adjusted in the stacking step during the production of the clothing fabric S, depending on the amount of the web that is to be formed, that is, the thickness of the web, and the like.

[0029] The thickness of the second layer L2 is not particularly limited, but is preferably, for example, 0.20 mm or more and 0.80 mm or less, which can improve the flexibility and strength of the clothing fabric S. The thickness of the second layer L2 is adjusted by the web thickness described above as well as the web pressure conditions in the molding process during the production of the clothing fabric S.

[0030] If the thickness of the second layer L2 is less than the lower limit of the above range, unevenness is likely to occur due to the variation in thickness. Therefore, if the second layer L2 is used on the front side of a garment, the first layer L1 on the back side may be visible through it. Therefore, it is preferable to suppress the variation in thickness of the second layer L2. However, the second layer L2 may have some parts of uneven thickness.

[0031] The second layer L2 may be surface-treated on the first face F1 in contact with the first layer L1 or on the second face F2 opposite to the first face F1. The surface treatment can improve various physical properties such as abrasion resistance.

[0032] The surface treatment is not particularly limited, but includes softening treatment, water repellency treatment, wrinkle prevention treatment, abrasion resistance treatment, etc. Known fiber treatment agents can be used for these surface treatments. For example, abrasion resistance treatment can suppress surface fluffing caused by rubbing of the garment, thereby maintaining a good appearance of the garment.

[0033] The surface treatment may be performed during the manufacturing process of the clothing fabric S, or after the clothing fabric S is manufactured. In particular, when the first surface F1 is surface treated, the second layer L2 and the first layer L1 are produced separately. Then, after the first surface F1 of the second layer L2 is surface treated, the first layer L1 and the second layer L2 may be bonded together to manufacture the clothing fabric S.

[0034] The fiber is one of the main components of the second layer L2, and together with the binder, it affects the physical properties of the cushioning material, such as its mechanical strength. The fiber is made by defibrating fabric. From the viewpoint of recycling resources, it is preferable to use old cloth such as old clothes for the fabric.

[0035] Fabrics include knitted fabrics, plain weave fabrics, pile fabrics, etc. Fabrics may also include nonwoven fabrics.

[0036] Examples of fibers include naturally derived fiber materials such as cotton, hemp, wool, silk, and regenerated cellulose, and synthetic fibers such as polypropylene, polyester, and polyurethane.

[0037] The fibers may be one of these alone or a combination of two or more. In particular, among the above-mentioned fiber materials, it is preferable that the fabric contains cotton or wool from the viewpoints of ease of obtaining used clothing and physical properties of the fibers.

[0038] The weighted average fiber length of the defibrated fibers is preferably 0.5 mm or more and 2.0 mm or less. This prevents the fibers from being excessively short, so that the fibers are appropriately entangled with each other, improving the mechanical strength of the second layer L2. The weighted average fiber length is determined by a method conforming to ISO 16065-2:2007.

[0039] The binder bonds the fibers together in the second layer L2. A thermoplastic or thermosetting resin is used as the binder. Examples of the resin include synthetic resins such as polyester, as well as natural resins such as shellac, rosin, dammar, polylactic acid, plant-derived polybutylene succinate, plant-derived polyethylene, and Kaneka Corporation's PHBH (registered trademark) (Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)). One of these may be used alone or two or more may be used in combination as the binder.

[0040] Examples of the treatment agent other than the binder include a coloring material for coloring the second layer L2 and various additives. Known pigments and dyes can be used as the coloring material. Examples of the additives include a flame retardant, an antioxidant, an ultraviolet absorber, an aggregation inhibitor, an antibacterial agent, an antifungal agent, a wax, and a mold release agent.

[0041] 2. Clothing fabric manufacturing method As shown in FIG. 2, the clothing fabric manufacturing method according to this embodiment includes a raw material supplying step S1, a fiber-opening step S2, a mixing step S3, a stacking step S4, a shaping step S5, and a cutting step S6.

[0042] In the clothing fabric manufacturing method, clothing fabric S is manufactured through each process in the above order from the upstream raw material supply process S1 to the downstream cutting process S6. The clothing fabric manufacturing method of the present invention includes the fiber-opening process S2, the mixing process S3, the stacking process S4, and the molding process S5, and the other processes are not limited to those described above.

[0043] A specific example of the clothing fabric manufacturing method will be described together with the fabric manufacturing device 1 that manufactures the clothing fabric S. The fabric manufacturing device 1 and the clothing fabric manufacturing method according to the present embodiment are merely examples, and are not limited to these.

[0044] 3, the fabric manufacturing apparatus 1 is equipped with, from upstream to downstream, a supply section 5, a crushing section 10, a defibrating section 30, a mixing section 60, a depositing section 100, a web transport section 70, a shaping section 150, and a cutting section 160. The fabric manufacturing apparatus 1 also includes a control section 28 that performs integrated control of the operation of each of the above components. The fabric manufacturing apparatus 1 manufactures clothing fabric S from fabric C.

[0045] The raw material supply step S1 is carried out in the supply unit 5. The supply unit 5 supplies the raw material to the coarse crushing unit 10. The supply unit 5 includes, for example, an automatic feed mechanism (not shown), and continuously and automatically feeds the raw material fabric C into the coarse crushing unit 10. The fabric C may be, for example, a material containing fiber such as old cloth.

[0046] The crushing unit 10 shreds the fabric C supplied from the supply unit 5 into small pieces in an atmosphere such as the air. The crushing unit 10 is a shredder or a cutter mill having a crushing blade 11. The fabric C is shredded into small pieces by the crushing blade 11. The planar shape of the small pieces is, for example, several mm square or irregular. The small pieces are collected in the fixed quantity supply unit 50.

[0047] The quantitative supply unit 50 weighs the small pieces and supplies a fixed amount to the hopper 12. The quantitative supply unit 50 is, for example, a vibrating feeder. The small pieces supplied to the hopper 12 are transported through the pipe 20 and reach the inlet 31 of the defibrating unit 30.

[0048] The defibration step S2 is carried out in the defibration unit 30. The defibration unit 30 defibrates small pieces of fabric C in a dry manner to generate fibers. The defibration unit 30 includes an inlet 31, an outlet 32, a stator 33, a rotor 34, and an airflow generating mechanism (not shown). The small pieces of fabric C are introduced into the defibration unit 30 through the inlet 31 by the airflow of the airflow generating mechanism.

[0049] The stator 33 and the rotor 34 are disposed inside the defibrating unit 30. The stator 33 has a substantially cylindrical inner surface. The rotor 34 rotates along the inner surface of the stator 33. The strips of fabric C are sandwiched between the stator 33 and the rotor 34, and are defibrated by the shear force generated between them.

[0050] The fibers produced in the defibrating unit 30 are discharged from the discharge port 32 into the pipe 40. The pipe 40 communicates with the inside of the defibrating unit 30 and the inside of the deposition unit 100. The fibers are transported from the defibrating unit 30 to the deposition unit 100 by the airflow generated by the airflow generating mechanism. A mixing unit 60 is provided in the pipe 40 between the defibrating unit 30 and the deposition unit 100.

[0051] The mixing step S3 is carried out in the mixing section 60. The mixing section 60 includes hoppers 13 and 14, supply pipes 61 and 62, and valves 65 and 66. The mixing section 60 mixes the treatment agent with the fibers in the air to generate a mixture.

[0052] The hopper 13 communicates with the inside of the pipe 40 via a supply pipe 61. A valve 65 is provided in the supply pipe 61 between the hopper 13 and the pipe 40. The hopper 13 supplies the binder into the pipe 40. The valve 65 adjusts the mass of the binder supplied from the hopper 13 to the pipe 40. This adjusts the mixture ratio of the fibers and the binder. The binder may be supplied in the form of a powder or particles, or may be supplied in a molten state.

[0053] The hopper 14 communicates with the inside of the pipe 40 via a supply pipe 62. A valve 66 is provided in the supply pipe 62 between the hopper 14 and the pipe 40. The hopper 14 supplies color materials and additives into the pipe 40. The valve 66 adjusts the mass of the color materials and additives supplied from the hopper 14 to the pipe 40. This adjusts the mixing ratio of the color materials and additives to the fibers and binder. The color materials and additives may be mixed with the binder in advance and supplied from the hopper 13.

[0054] The fibers, binder, etc. are mixed to form a mixture while being transported through the pipe 40 to the deposition unit 100. To promote the generation of the mixture in the pipe 40 and to improve the transportability of the mixture, a blower that generates an air current or the like may be provided in the pipe 40. The mixture is introduced from the pipe 40 to the deposition unit 100 via the connection unit 42.

[0055] The deposition step S4 is carried out in the deposition unit 100. The deposition unit 100 deposits the mixture in the air on the breathable fabric N that is to become the first layer L1 of the clothing fabric S, to generate a web W that is to become the second layer L2. In other words, the second layer L2 is formed by depositing a mixture containing defibrated fibers and a treatment agent in the air on the fabric N that is to become the first layer L1. Therefore, the second layer L2 can be easily formed. Also, the basis weight can be easily changed.

[0056] The deposition unit 100 has a drum unit 101, a housing unit 102 that houses the drum unit 101, and a dough supply unit 71 that supplies dough N. The deposition unit 100 takes in the mixture from the pipe 40 into the inside of the drum unit 101. Then, the mixture is deposited on the dough N supplied from the dough supply unit 71 in a dry manner.

[0057] A web transport unit 70 including a mesh belt 122 and a suction mechanism 110 is disposed below the deposition unit 100. The suction mechanism 110 is disposed opposite the drum unit 101 with the mesh belt 122 interposed therebetween in the direction along the Z axis.

[0058] The drum unit 101 includes a blade member 101a that is driven to rotate by a motor (not shown), and a substantially cylindrical sieve unit 101b that is disposed to cover mainly the lower part of the blade member 101a. The blade member 101a loosens tangled fibers as it rotates. The sieve unit 101b passes particles such as fibers and mixtures that are smaller than the mesh size of the sieve from the inside to the outside. As a result, the tangled fibers of the mixture are loosened in the drum unit 101, and dispersed into the air in the housing unit 102.

[0059] The fabric supplying unit 71 continuously sends out the roll-shaped fabric N onto the mesh belt 122. At this time, the adhesive layer L1a of the fabric N faces upward. If a release paper is attached to the adhesive layer L1a of the fabric N, the fabric supplying unit 71 may include a separation mechanism that separates the release paper from the fabric N.

[0060] The mixture containing fibers is dispersed from the inside of the sieve unit 101b into the air in the housing unit 102. Then, the mixture containing fibers is randomly piled up above the fabric N transported on the mesh belt 122. Therefore, it becomes difficult for the fibers in the web W to be oriented in a specific direction.

[0061] The sieve unit 101b does not need to have a function of separating large fibers and the like in the mixture. That is, the drum unit 101 may loosen the fibers of the mixture and release all of the mixture into the inside of the housing unit 102. The mixture dispersed in the air in the housing unit 102 is deposited on the surface above the fabric N by gravity and the suction force of the suction mechanism 110.

[0062] The basis weight of the clothing fabric S is adjusted by the basis weight of the fabric N and the web W. The basis weight of the web W is adjusted by the rotation speed of the blade members 101a, the amount of the mixture supplied per hour to the deposition section 100, the conveying speed of the fabric N by the mesh belt 122, etc.

[0063] The mixture ratio of the fiber and the treatment agent is not particularly limited and is adjusted appropriately depending on the type of the treatment agent. For example, when a binder is used as the treatment agent, the mass ratio of the fiber to the binder in the web W is preferably in the range of 9:1 to 5:5 in terms of fiber to binder. This ensures a balance of the physical properties of the clothing fabric S.

[0064] The web transport section 70 includes a mesh belt 122 and a suction mechanism 110. The web transport section 70 promotes deposition of the mixture on the fabric N by the suction mechanism 110. In addition, the web transport section 70 transports the web W formed from the mixture downstream by the rotation of the mesh belt 122.

[0065] The suction mechanism 110 is disposed below the drum unit 101. The suction mechanism 110 sucks in the air inside the housing unit 102 through a plurality of holes in the mesh belt 122 and the breathable fabric N. As a result, the mixture discharged to the outside of the drum unit 101 is sucked downward together with the air and piled up on the upper surface of the fabric N. A known suction device such as a blower is used for the suction mechanism 110.

[0066] The mesh belt 122 has a plurality of holes that allow air to pass through but prevent fibers, binders, etc. contained in the mixture from passing through. The mesh belt 122 is an endless belt and is stretched around four tension rollers 121.

[0067] The mesh belt 122 has its upper surface moving downstream due to the rotation of the tension roller 121. In other words, the mesh belt 122 rotates clockwise in FIG. 3. As the mesh belt 122 is rotated by the tension roller 121, the mixture is continuously deposited to form the web W. The web W contains a relatively large amount of air and is soft and inflated. The web W, together with the fabric N, is transported downstream as the mesh belt 122 moves.

[0068] A humidifier 130 may be disposed downstream of the deposition section 100 to humidify the web W by spraying water thereon. This prevents fibers, binders, and the like contained in the web W from scattering. In addition, a water-soluble treatment agent may be added to the water used for humidification, and the web W to become the second layer L2 may be subjected to a surface treatment in parallel with the humidification.

[0069] The web W and fabric N are transported downstream by the mesh belt 122, peeled off from the mesh belt 122, and drawn into the dancer roller 141. The dancer roller 141 is provided to ensure the processing time of the downstream forming step S5. In detail, since the forming step S5 following the deposition step S4 is a batch process, the dancer roller 141 is moved up and down with respect to the web W and fabric N continuously supplied from the deposition unit 100 to ensure the processing time of the forming step S5. The web W and fabric N reach the forming unit 150 via the dancer roller 141.

[0070] The forming step S5 is carried out in the forming unit 150. In the forming step S5, the web W is heated and pressurized together with the fabric N to form a belt-shaped clothing fabric S. The forming unit 150 is a heat press device and includes an upper substrate 152 and a lower substrate 151. The upper substrate 152 and the lower substrate 151 pressurize the web W and the fabric N while sandwiching them therebetween, and heat the web W and the fabric N with built-in heaters. Note that in the forming step S5, the forming step S5 may be carried out continuously using a pair of heating rollers or the like.

[0071] The web W is compressed from above and below by pressure, increasing its density, and the binder melts and spreads between the fibers by heating. When the heating is stopped in this state and the binder solidifies, the fibers are bonded together by the binder. The fabric N and the web W are then stuck together, with the fabric N forming the first layer L1 and the web W forming the second layer L2.

[0072] The conditions for pressurization and heating in the forming section 150 are appropriately adjusted depending on the desired density of the clothing fabric S and the melting point or hardening temperature of the binder. Although not particularly limited, the pressurization condition is, for example, 0.01 MPa or more, and the heating condition is, for example, 90° C. or more. The fabric N and the web W are made into a belt-shaped clothing fabric S by the forming section 150, and proceed to the cutting section 160.

[0073] The cutting step S6 is carried out in the cutting section 160. The cutting section 160 adjusts the shape of both ends of the belt-shaped clothing fabric S. The cutting section 160 includes a vertical blade (not shown).

[0074] The vertical blade cuts the belt-shaped clothing fabric S in the direction along the travel direction. This causes both ends of the clothing fabric S to be cut evenly. The belt-shaped clothing fabric S is then wound into a roll to become a bolt of cloth. The cutting section 160 may also include a horizontal blade that cuts in a direction intersecting the travel direction of the clothing fabric S. In this case, the clothing fabric S is cut into single pieces of approximately rectangular shape, etc. The clothing fabric S is manufactured in this manner.

[0075] The clothing fabric manufacturing method of this embodiment may include, in addition to the steps described above, a step of performing the above-mentioned surface treatment on the second layer L2, and a step of coloring the first layer L1.

[0076] According to this embodiment, the following effects can be obtained.

[0077] The thinness and strength of the clothing fabric S can be improved. More specifically, the strength is improved because the second layer L2, which is a nonwoven fabric containing defibrated fibers, is reinforced by the first layer L1. This makes it possible to reduce the thickness while ensuring the strength of the clothing fabric S. This makes it possible to provide a clothing fabric S that is both thin and strong, and a method for manufacturing the clothing fabric.

[0078] 3. Examples and Comparative Examples The effects of the present invention will be described in more detail below with reference to examples and comparative examples. FIG. 4 shows the layer structure, manufacturing conditions, and evaluation results for the clothing fabrics S of Examples 1 to 5 and Comparative Examples 1 to 8. In the following description, Examples 1 to 5 are sometimes collectively referred to as simply Examples, and Comparative Examples 1 to 8 are sometimes collectively referred to as simply Comparative Examples. The present invention is not limited in any way by the following examples.

[0079] 3.1. Preparation of test pieces for evaluating clothing fabrics As shown in Fig. 4, in Example 1, a blended fabric made of cotton and polyester was used as the raw material fabric C of the fibers. Specifically, in the raw material supplying step S1, the knitted fabric was roughly crushed into approximately rectangular pieces with long sides of 1 mm to 30 mm using a cutter mill manufactured by Makino Sangyo Co., Ltd. Next, in the defibrating step S2, the small pieces were defibrated to form fibers in the same manner as in the defibrating step S2 of the above embodiment.

[0080] Next, in the mixing step S3, the fibers and the binder were mixed in a mass ratio of 10:3 by air agitation. Then, in the deposition step S4, the mixture was deposited on the fabric N in the air to form the web W. At this time, the basis weight of the second layer L2 was 100 g / m 2The amount of mixture deposited was adjusted so that the thickness was 0.1 mm. A polyester nonwoven fabric with a thickness of 0.1 mm was used as the material N. A thermoplastic resin was used as the binder.

[0081] Next, in the forming step S5, the web W and the fabric N were subjected to a hot press. At this time, an AF-54TEN (product name) made by Itsumi Co., Ltd. was used as the hot press machine, and the heating conditions were 150°C for 1 minute, and the pressure conditions were such that the thickness of the second layer L2 in the clothing fabric S was 0.31 mm, to produce the clothing fabric S of Example 1. The second layer L2 of Example 1 was not subjected to a surface treatment. Then, in the cutting step S6, the web W and the fabric N were cut with a cutter into single pieces of 250 mm length and 100 mm width to prepare test pieces for evaluation.

[0082] In Example 2, the basis weight of the second layer L2 is 160 g / m 2 compared to Example 1. 2 and the thickness of the second layer L2 was 0.90 mm. In addition, a test piece was prepared in the same manner as in Example 1, except that the molding step S5 was not performed and the first layer L1 and the second layer L2 were bonded together by hand.

[0083] In Example 3, the basis weight of the second layer L2 is 160 g / m 2 compared to Example 1. 2 A test piece was prepared in the same manner as in Example 1, except that the thickness of the second layer L2 was 0.78 mm.

[0084] In Example 4, the basis weight of the second layer L2 is 160 g / m 2 compared to Example 1. 2 The thickness of the second layer L2 was 0.75 mm. The web W was formed independently without being formed on the material N, and the surface treatment was performed, and then the molding step S5 was carried out. As the surface treatment, abrasion resistance treatment was performed using the surface treatment agent A.

[0085] Specifically, OXAL-HX (product name, blocked isocyanate-based crosslinking agent) manufactured by Epson Como Printing Technologies Srl was used as the surface treatment agent A. The surface treatment agent A was prepared as an aqueous solution with a concentration of 100 g / L. Then, as a surface treatment, the web W was impregnated with the solution using a padder, which is an impregnation device. Then, the web W was dried at 160° C. for 3 minutes. In this case, as a surface treatment, both the first surface F1 and the second surface F2 of the second layer L2 were subjected to the surface treatment. A test piece was prepared in the same manner as in Example 1 except for the above.

[0086] In Example 5, the thickness of the second layer L2 was set to 0.70 mm, and after the abrasion resistance treatment, a softening treatment was performed as an additional surface treatment using the surface treatment agent B. A test piece was prepared in the same manner as in Example 4 except for the above.

[0087] For the softening treatment, FORDEEP SOF (product name, silicone-based softener) manufactured by Epson Como Printing Technologies Srl was used as the surface treatment agent B. The surface treatment agent B was prepared as an aqueous solution with a concentration of 50 g / L. Then, as the surface treatment, the web W was impregnated with the above solution using a padder, which is an impregnation device. Thereafter, the web W was dried at 160°C for 3 minutes. In this case, as an additional surface treatment, the above surface treatment was performed on both the first surface F1 and the second surface F2 of the second layer L2.

[0088] In the comparative clothing fabric, the fabric N to become the first layer L1 was omitted, and the molding step S5 was not performed. Specifically, in the comparative example 1, the basis weight of the second layer L2 was 100 g / m 2 The thickness of the second layer L2 was set to 0.28 mm, and the molding step S5 was omitted. A test piece was prepared in the same manner as in Example 2 except for the above.

[0089] In Comparative Example 2, the first layer L1 was omitted, and the basis weight of the second layer L2 was set to 100 g / m 2 and the thickness of the second layer L2 was 0.29 mm. Except for the above, the same procedure as in Example 4 was carried out to prepare a test piece.

[0090] In Comparative Example 3, a test piece was prepared in the same manner as in Comparative Example 2, except that a softening treatment similar to that in Example 5 was solely carried out instead of the abrasion resistance treatment.

[0091] In Comparative Example 4, a test piece was prepared in the same manner as in Comparative Example 2, except that the thickness of the second layer L2 was 0.30 mm and both the abrasion resistance treatment and the softening treatment were carried out in the same manner as in Example 5.

[0092] In Comparative Example 5, the basis weight of the second layer L2 is 160 g / m 2 compared to Comparative Example 1. 2 A test piece was prepared in the same manner, except that the thickness of the second layer L2 was set to 0.87 mm.

[0093] In Comparative Example 6, the basis weight of the second layer L2 is 160 g / m 2 compared to Comparative Example 2. 2 A test piece was prepared in the same manner, except that the thickness of the second layer L2 was set to 0.88 mm.

[0094] In Comparative Example 7, the basis weight of the second layer L2 is 160 g / m 2 compared to Comparative Example 3. 2 A test piece was prepared in the same manner, except that the thickness of the second layer L2 was set to 0.88 mm.

[0095] In Comparative Example 8, the basis weight of the second layer L2 is 160 g / m 2 compared to Comparative Example 4. 2 A test piece was prepared in the same manner, except that the thickness of the second layer L2 was set to 0.88 mm.

[0096] 3.2. Evaluation of clothing fabrics The test pieces of the examples and comparative examples were evaluated for strength, color development, fluffing, and texture. The evaluation results for each level are shown in FIG.

[0097] 3.2.1. Strength evaluation The following procedure was carried out to evaluate the strength. Both ends of the test piece in the longitudinal direction were held in each hand, and the areas held by each hand were overlapped and rubbed together for 3 minutes. At this time, the surfaces rubbed together were the surface of the second layer L2. After that, each test piece was checked for the occurrence of breakage and evaluated according to the following criteria. If a breakage occurred during the rubbing operation, the time when it occurred was recorded and the subsequent rubbing operation was discontinued. Evaluation criteria A: No tears occurred even after rubbing for 3 minutes. B: Breaking occurred after rubbing for 2 minutes or more but less than 3 minutes. C: Breaking occurred after rubbing for 1 minute or more and less than 2 minutes. D: Breaking occurred after rubbing for less than 1 minute.

[0098] 3.2.2.Evaluation of color development To evaluate color development, a commercially available textile inkjet printer (pigment ink) was used to print black ink on the surface of the second layer L2 of each test piece, and the print quality was visually evaluated. Specifically, a Seiko Epson Monna Lisa (registered trademark) Evo Tre16 was used as a textile inkjet printer to perform solid printing in black (printing duty: 100%) on almost the entire surface of the second layer L2 of the test piece. After the ink dried, it was evaluated according to the following criteria. A: There were no printing unevenness and good color development was obtained throughout the entire printed area. B: Some printing unevenness was observed, but color development was sufficient for practical use. C: Printing unevenness was observed in various places, and color development sufficient for practical use was not achieved.

[0099] 3.2.3. Evaluation of pilling The rubbing operation was carried out for each test piece in the same manner as in the evaluation of strength described above. At this time, the rubbing operation was interrupted every 10 seconds, and the degree of fuzzing on the surface of the rubbed test piece was observed each time. The rubbing evaluation was stopped when fuzzing occurred, and the cumulative rubbing time at that point was recorded. If fuzzing did not occur, the rubbing operation was carried out until the cumulative rubbing time reached 2 minutes. The time when fuzzing occurred and the presence or absence of fuzzing were evaluated according to the following criteria. A: No pilling occurred even when rubbed for more than 1 minute but less than 2 minutes. B: Pilling occurred when rubbing for more than 20 seconds but less than 1 minute. C: Pilling occurred when the material was rubbed for more than 10 seconds but less than 20 seconds. D: Pilling occurred when rubbed for 10 seconds or less.

[0100] 3.2.4. Evaluation of texture A sensory evaluation of the feel was conducted to evaluate the texture. Specifically, 50 evaluators touched each test piece with their hands and tallied their scores for the feel. The tallied results were evaluated according to the following criteria. A: 95% or more of all evaluators rated the feel as good. B: 80% or more and less than 95% of all evaluators evaluated the feel to be good. C: 40% or more and less than 80% of all evaluators evaluated the feel to be good. D: Less than 40% of all evaluators rated the feel as good.

[0101] 3.3. Summary of evaluation results As shown in FIG. 4, in the strength evaluation, the Examples were rated A or B at all levels. On the other hand, the Comparative Examples were rated C or D at all levels. In detail, the thickness of the second layer L2 is similar between Example 1 and Comparative Examples 1 to 4, and between Examples 2 to 5 and Comparative Examples 5 to 8. Even when comparing samples with similar thicknesses, the Examples have a significant improvement in strength compared to the Comparative Examples. In particular, Example 1 was rated A, even though the second layer L2 is relatively thin at 0.31 mm. From the above, it was shown that the test pieces of the Examples are both thin and strong.

[0102] In the evaluation of color development, the Examples were rated A or B at all levels, and the Comparative Examples were rated C at all levels. In the evaluation of fluffiness, the Examples were rated A or B at all levels, and the Comparative Examples were rated C or D at all levels.

[0103] In the evaluation of texture, all levels of the Examples were rated A or B, and all levels of the Comparative Examples were rated C or D. In particular, Examples 2 to 5 were shown to have a good texture, even though the thickness of the second layer L2 was similar to those of Comparative Examples 5 to 8.

[0104] From the above, it was shown that the test pieces of the Examples were superior to the test pieces of the Comparative Examples in terms of color development, resistance to fluffing, and texture. [Explanation of symbols]

[0105] C...Fabric, F1...First side, F2...Second side, L1...First layer, L1a...Adhesive layer, L1b...Base material layer, L2...Second layer, N...Fabric, S...Clothing fabric, S2...Defibration process, S3...Mixing process, S4...Deposition process, S5...Forming process, W...Web.

Claims

1. a first layer having breathability; and a second layer formed by mixing the defibrated fibers with a treatment agent.

2. the second layer is a nonwoven fabric; The second layer has a basis weight of 100 g / m 2 More than 180g / m 2 2. The clothing fabric of claim 1, wherein:

3. 3. The clothing fabric according to claim 2, wherein the second layer is formed by depositing a mixture containing the defibrated fibers and the treatment agent on the first layer in the air.

4. The clothing fabric of claim 1 , wherein the first layer comprises a base layer and an adhesive layer interposed between the base layer and the second layer.

5. The clothing fabric of claim 4 , wherein the base layer comprises polyester.

6. The clothing fabric of claim 1 , wherein the first layer is colored.

7. The clothing fabric according to claim 1 , wherein the second layer is surface-treated on a first surface in contact with the first layer or a second surface opposite to the first surface.

8. 2. The clothing fabric according to claim 1, wherein the weighted average fiber length of the fibers is 0.5 mm or more and 2.0 mm or less.

9. A defibration process for dry-defibrating the fabric to generate fibers; a mixing step of mixing a treatment agent with the fibers to form a mixture; depositing the mixture in air onto a breathable fabric forming a first layer to produce a web forming a second layer; and a molding step of pressurizing and heating the fabric and the web to mold them.

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